Kawasaki Bayou 300 engine swap - Kawasaki KLR 650 Forum
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post #1 of 9 Old 12-08-2015, 11:22 AM Thread Starter
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Kawasaki Bayou 300 engine swap

Hello guys! My name is Michael. I recently performed a motor swap on my Kawasaki Bayou 300 4x2. Upon initial start up (1-2 minutes of running) I noticed oil pouring out the rear seal of the transmission. The seal was damaged. I don't know if the transmission if pressure lubricated or vacuum lubricated. The engine sounded good, but I was concerned that the engine may not have been lubricating properly with the possible loss of pressure due to the leak. I just performed an oil change so initially the oil level was full. It probably leaked 1/2-3/4 of a quart. Of course I cut the engine off as soon I realized this. I just want peace of mind that the top end of the motor was still getting lubricated. Thanks for any insight or piece of mind you guys can give me. Thanks!
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post #2 of 9 Old 12-08-2015, 02:42 PM
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Hey welcome to the forum. We're primarily KLR 650 owners here but you may get an answer to your question. Hoping PDWestman jumps in. I've got a Bayou 400 myself.

My Kaw Barn - 2004 KLR, 2006 Concours (sold), 1997 Bayou 400.

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post #3 of 9 Old 12-08-2015, 03:52 PM
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Bayou 300 4X4 rider, myself!

My assessment: Don't worry, be happy! Chances are, no oil starvation damage occurred to the top end as a result of the quickly-detected oil seal leak.

Fix it, top off the oil, and ride it forever, as is its destiny!
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post #4 of 9 Old 12-08-2015, 04:56 PM
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Quote:
Originally Posted by Foster.1 View Post
Hello guys! My name is Michael. I recently performed a motor swap on my Kawasaki Bayou 300 4x2. Upon initial start up (1-2 minutes of running) I noticed oil pouring out the rear seal of the transmission. The seal was damaged. I don't know if the transmission if pressure lubricated or vacuum lubricated. The engine sounded good, but I was concerned that the engine may not have been lubricating properly with the possible loss of pressure due to the leak. I just performed an oil change so initially the oil level was full. It probably leaked 1/2-3/4 of a quart. Of course I cut the engine off as soon I realized this. I just want peace of mind that the top end of the motor was still getting lubricated. Thanks for any insight or piece of mind you guys can give me. Thanks!
Foster.1,
I'm going to ask if the rear drive shaft/axle assembly was Not Yet installed? If it was, was the bellows not yet engaged? The bellows protects the carrier bearing and the seals on Both ends of the drive shaft from mud and water.

The drive splines are oil Wet. Therefore the output seal seals on the OD of the driveshaft. I'm almost surprised that the engine oil wasn't running out as you were pouring it in.
(I don't have one in here to measure oil window vs output seal height.)
There is an oil feed line and specific sized banjo fitting which feeds that area.
As others said, probably no harm done in your test start.

pdwestman
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Still riding my 1987 KL650-A1. 85,000+ miles & counting
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post #5 of 9 Old 12-11-2015, 06:54 AM
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If idle is the problem, two things come to mind:

IDLE SPEED SCREW: This adjustment is made from the left side of the carburetor; a plastic knob, affixed to a cable under the carb, can be turned to increase or decrease idle speed (clockwise increases, counter-clockwise decreases.

IDLE MIXTURE SCREW. This screw is found beneath a tamper-resistant cap (which must be removed for adjustment) on the bottom of the carb body on the engine side. A nominal adjustment point would the 1-3/4 turns out from a soft bottoming; adjustments can be made from there for optimum idling.

If the carb is all gunked up, chances are the idle mixture screw, spring, washer, and packing should be removed, cleaned, and carefully re-assembled.

I strongly refer you to two references accessible from this website (both about the CVK40 carb, but applicable to the Bayou 300's CVK32):

Care & Feeding Of The Keihin Carb

http://www.klrforum.com/how-tos-tech...-overhaul.html

Please visit these links before further discussion about the Bayou carb.

I do not think a larger pilot jet will solve your problem.
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post #6 of 9 Old 12-11-2015, 11:12 PM
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Uh.... Did you post this in the wrong thread Damoclese?? Or did I miss something?
JJ


Quote:
Originally Posted by Damocles View Post
If idle is the problem, two things come to mind:

IDLE SPEED SCREW: This adjustment is made from the left side of the carburetor; a plastic knob, affixed to a cable under the carb, can be turned to increase or decrease idle speed (clockwise increases, counter-clockwise decreases.

IDLE MIXTURE SCREW. This screw is found beneath a tamper-resistant cap (which must be removed for adjustment) on the bottom of the carb body on the engine side. A nominal adjustment point would the 1-3/4 turns out from a soft bottoming; adjustments can be made from there for optimum idling.

If the carb is all gunked up, chances are the idle mixture screw, spring, washer, and packing should be removed, cleaned, and carefully re-assembled.

I strongly refer you to two references accessible from this website (both about the CVK40 carb, but applicable to the Bayou 300's CVK32):

Care & Feeding Of The Keihin Carb

http://www.klrforum.com/how-tos-tech...-overhaul.html

Please visit these links before further discussion about the Bayou carb.

I do not think a larger pilot jet will solve your problem.

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post #7 of 9 Old 12-12-2015, 05:34 AM
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Originally Posted by justjeff View Post
Uh.... Did you post this in the wrong thread Damoclese?? Or did I miss something?
JJ
Reckon so!

In my muddled mind, I thought someone posted about an idle problem with a Bayou 300.

Since this thread is Bayou 300-related, I just disgorged the wisdom in my post!

Bandwidth used in vain, or . . . maybe whoever posted about the Bayou 300 idle (if anyone ever did) will read it!

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post #8 of 9 Old 12-12-2015, 11:43 AM
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You are at it again, Jim!

You simply have to rein in that precognition and wait a week or so for the question to be asked before you answer it. ;-)

It's either pre-cog or my memory problem and hope it's not the second. ;-)
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post #9 of 9 Old 12-12-2015, 04:06 PM
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From another website? Doesn't seem ADVesque.

My flawed memory recalls someone with idle problems vis-a-vis a Bayou 300 (NOT 4X4). He thought he needed a larger pilot jet . . .

If entirely imaginary, here's a ready-made solution, waiting for its problem!
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